Process of making storage-battery electrodes.



' and cobalt, or nickel alone.

active material,

. tain, except under considerable pressure, and

- tivepa-rticles and bulging of the pocket walls,

tofore been a limit'at-which the further conmetallic contacts within the electrode are en- U I ED STATES PATENT OFFICE.

THOMAS unison, or LLEwELLYN PARK, ORANGE, rmvinasnY, ASSIGXOR TO EDISON STORAGE BA. TERY OOMPANY, or wnsr ORANGE, NEW JERSEY, A- CORPORATION OF NEW JnnssY.

rnocnss' or fnaxme STORAGE-BATTERY-ELECTRODES. I :V 1

Specification of Letters Patent. Patented March 2, 1 909.

252,929. Divided and this application filed May 17, 1907 Serial No. 374,306.

No. 914,343. i I Original application filed March 30, 1905, Serial No.

D the formation of the latter, so that-obviously, Be. it known that I, THOMAS A. 'Emsox, a free passage will be allowed for the escape of citizen of the United State's, and a resident of anygas generated in situ. Byso constructing Llewellyn Park, Orange, in the county of the conducting metal that it shall constitute l a honeycomb or sponge-like cellular structure Essex and State of New Jersey,.; have invented a certain new and Improved Process l within the pocket or other electrode element and by allowing free opportunity for the for Makin Stora e-Batter Electrodes of D O y l escape of gas generated therein, the tendency which the folldwing is a description.

T his apphcation is a division of my Patent ofstheelectrode mass, as a whole, to swell is very largely reduced, and for this reason the No. 882,144, granted March 17, 1908.

My invention relates to an improved, procnecessity ofemploying expensive and highly elastic steel is overcome; moreover the ess for making a storage battery electrode, wherein the active material is associated with cheaper steel, if used, can be more readily and economically perforated, Furthermore,

minute flakes or foils of an insoluble metal or metals, preferably-cobalt or an alloy of nickel by employing an integral metallic spongelike conducting system,

In using metal- 110 conducting flakes for admixture with the conductivity of the stant and as it presents cells of minute, size,

To all whommwyconcern;

difliculties have been experienced, due in the first place, to the fact that electrical contact between the metallic flakes and between the flakes and the pocket walls is generally poor and difiicult to mainbe relatively slight (probably not greater than one or two particles thick) so that it will be necessary for the current to traverse paths of the minimum length through-the active particles, thus allowing an enormously high discharge rate. By impregnating the cells of the conducting st1ucture,j,as hereinafter described, I am furthermore enabled to remove the active material flwhenever necessary, after which the eonducting structure may be cleaned by hydrogen and re-used with fresh active materials Furthermore, the process of forming the conducting. metallic sponge or cellular structure within the pockets, as explained, also results in the welding of the pocket sections so in the second place, to the fact that opportunity is ofiered within the mass for the trap ping of gas, resulting in separation of the acto further increase the difficulties of contact. The latter objection is more pronounced when the battery solution employed is quite concentrated and hence in the best condition for high economy, owing to the viscous character thereof. Consequently, there'has herecentratidn of the solution cannot be carried without serious objection.

By my improved process I provide an improved storage battery electrode, wherein that a structure will be secured wherein all metallic contacts are eliminated, the advantages of which are obvious. I

Assuming the mechanical make-up of the tirely done away with, and wherein very much less opportunity isoiiered for gas press electrode to be substantially like that lllussure due to solution viscosity, and or traptrated in my Patent NO. 704,305, dated July of gas with the objections noted. 8, 1902 ,-.I proceed substantially as follows: I

first take asuitable refractory material capable of being readily dissolved when desired, such as magnesium oxid, and mix' it with a small quantity of water containing a little carbonate .of soda or other suitable binder.

To this end, the invention consists of a process for producin a storage battery electrode, wherein the fia es of conducting metal or metalsalre welded-together and to the pocket walls, if used, presenting a highly diversified cellular integralstructure with a .verysmall weight of metal, in which the active material is intimately contained, the process of manufacture being such that the active material is introduced within the cellular structure after ten the oxid, so that after thorough mixing the'oxid shows a tendency to cake together orpack-slightly. This mass is then molded into thin cakes undervhydraulic pressure and Only enoughwater is added to slightly mois-' as explained, the latter alyvay the thickness of active material in ,contact with any part of the conducting systemwillflthe cakes are subjected toia white heat, so as" to.. consolidate the same and make them fairly hard. The 'cakes'are then crushed to form granules of fairly definite size which are then screened. Those particles passing a I mesh-screen and'rejected byfan 80 mesh screen are first mixed with water, then dried,

and arethen mixed witha suitable sticky material, preferably 'stifl molasses, until the exteriorsu'rface of all the articles is coated 'withthe latter. I'nowad' the thinimetallic flake likeconducting metal or metals (prefeera'b l' cobalt or a cobalt-nickel". alloy, or

'nicke alone) in the form of relatively smallfilms or scales in substantially the proportion of twenty-four parts by weight of the granualloy made by fusion, may be rolled into.

flakes, oil being used to prevent sticking, as

lar oxid and five partsby weight of the 'con-' ducting metal, andintimately'mix the same. O'wingto the 1presence of the thinsticky film 20 thereof will 'be' coated with the flake-likeon each of t e oxid'granules, the surface metal,,-so that when the mixing is complete the resulting massshows to the eye nonefof" the white oxid, but appearsto consis t en'- .tirely'of metallic anules. 1 a

' The metallic akes referred .to may be made in any'suitable way;- for example, thin sheetsof cobalt .or nickel, or; a nickel-cob alt iswell known, for instance, in the art of making bronze owder'. Or instead,:.- the hy- 2 droxid of eit er metal, or the mixed-hydrox- .size, and" after re ids of both'metals in the'proper pro ortion canfbe recipitated in the usua way,

washed,' rie'dand (granulated to the"proper uction by hydrogen or otherwise, passed between rolls with oil to form the flakes, as-I'describe in my Patent No.:827-,71 7, granted August 7tl1,1906. .In

either case, it is desirable to anneal the flakes two. ormore times between the passes of the rolling operation in an inert gas,'pref.erably hydrogen, at a redheat, After the flakes are formed, it .is preferable, in order to increase their bulk, to ass them between very ffine .crimpingrolls' y which: they .will be nute curved flakes;

crimped, corru ated or otherwise distorte(l,-.

of very small diameter bywhich they will becurled or formed into 'nu-' Or instead, the flakes or r or between rol foils may be made by a process of'electro= 'eration maybe dispensed with, since electrode )osited hlms naturallyassume curved or a deposition as I describe in my Patent No.- 821,626, granted May: 29th, 1906, in which event the subsequent crimping orfilrling op coi edforms. For construction of the flakes or scales, or foils, I findthat metallic nickel, although perfectly insoluble, possesses the objection that good contact with-the active materialcannot-be secured unless-an undesirably high pressure is employed. can be possibly attributed to the formation of an invisible film of non-conducting oxidby tions to ether 'andlock t the gri This fact desirable to rely on metallic cobalt alone. I

therefore prefer to make use of 'a nickel-co- 'ba'lt alloy, containing sa'y' -60 per' enhx f v balt and 40 per cent. of nickel. With-such an g alloy good contact with *the active imaterial' willbe secured by the'mere weight of the latter without additional pressure, while atgthe same time, oxidationof thecobalt will not penetrate into the alloy to a harmful extent, 55

:so. that the flakes will preserve their metallic identity.) This desirable characteristic ofthenickel cobalt alloy "is present even when the proportions of the two metals are-widely varied.- 3

The mixture secured by adding the flakes to the coated particles is dried, andlis prefer- 'ably introduced within the usual sectional 1 pockets which are assembled in the grid *and yd'raulic pressure applied, as I ,descri e in my said patent, to. enga e the; pocket -sec- Tie latter-firmly in The grid now immersed in slightlyalkaline water (say+atwo per cent. solution of potassium hydroki'd) until the mo 'la'sses has entirel percolated out of the ma s, which can be efl ected by -'several changes if the solution, after whichtjthei electrode is again-subjectedto pressu Theelectrode isnow' dried, and is placed ma retort-through '1 05 which hydrogen is-passed, and brought to a v bright-yellow heat. Thepresence of the hy- 'dro en atmosphere prevents any .jbxidationl of t e-metal at the heat used, and-the two sections of' each pocket will be thus Welded to' I one another, and the metallic flakes or foils distributed throughout the mass will bealso welded together and to the pocket sectiims. In other words, by this 'weldmgoperation, integrality of the entire metallic parts of the electrodes is secured, so' as to entirely eliminate metallic contacts in the electrode sy's tem'. Furthermore, by Weldingtogetherthe vmetallic flakes Within the "pockets, free op- 12o portunity for the escape of-gas-is allowed, reducing the dangerof gas pressure arising in the .activemass, -a'nd permittin a much cheap'erjgrade of steel to be emp loyed. It." will of.course, be understood "that the heat applied is sufiicient-onlymto eflect a-welding V operation and not sufficient to result melt: ing the metal enough to cause itto flow. -After the Welding operation thus described. has

been efl'ected,' it becomes necessary-to re-. p move the granular magnesium oxld, since the 130 A t r t electrode dried, the electrode plate is preferout the oxid in any suitable way, as for example, in dilute acetic acid, which does-not sensibly attack the metallic part-s.

sult of theoperations so far followed ,1 obtain a structure in which-the usual perforated pockets are loosely filled with a line, quite soft, pithy, readily compressible, sponge-like ,or honeycomb mass of insoluble metal or alloy, presenting irmumerable cells all connected together, and, in bulk occupying only ,a; fraction of the available space'inclosed by I each pocket and of such a character as to make good contact with the active material. acid has beenwashed out and the ably subjected in a hydrogen atmosphere to ufii cient to effect a further welding, I fficient to effectively clean all the me '2 he in but unit surfaces and reduce any oxid present, so {as to permit perfect contact with the active material (for example, nickel hydroxid) which 'tnow becomes necessary to introduce within the cellular mass. This is done by {introducing the electrodes in a closed chamber connected to a vacuum pump, and whose walls may behe'ated, for instance, by a steam jacket. I now introduce Within the inclosed chamber by means of apump, a saturated solution of asuitable nickel salt, preferably an ammoniacal solution of nickel hydroxid,

made by dissolvingito saturation, nickel sesquioxidin ammonia. This saturated ammoniacalsolution enters at the bottom of the chamber, and as the level rises all the pores or and 1 vacuum pum -like structure will be filled with the same. The surplus solution is now withdrawn from the impregnating chamber, capillarity' preventing the escape of the solution from the sponge-like structure, the

cells of the spong' yevaporate the ammonia and deposit of nickelous bycells, the 'am monia being absorbed in water o r otherwise recovered. By re eating these operations .many times, the ce ls may be al st entirely with the aotivehydroxid, care being of course taken to use at all times asaturated solution,- in order that the active material deposited within out during the succeeding operations. By depositing layers onthe Walls of the cells, as explained, itis possible to pli d to q i water, leavlng a numerous minute connected channels, extending in all directions, throughout the mass and leading to the surface thereof, and

through which any gas generated within the mass may freely escape.

The electrodes thus formed are now removed, the exterior As a rea 1s operated, and heat is ap the cells shall not be dissolved the active material in successive? so regulate the amount of aci tive material thus introduced, as to prov de m I surfaces freed from any OXld which may adhere to the same, and after being subjected I to pressure to consolidate the metallic sponge E on the active material, are ready foruse.

ways than by the process above indicated.

I For instance, any other suitable inert refrac solved or otherwise removed may be employed, instead of a magnesium oXid, such as ignitet'l t-ricalcic phosphate, in granular form. With this material the operations are the same as those followed with magnesium oxid. It is also possible to omit the granular material. and introduce. the corrugated ior curved flakes or foils loosely into the i )ockets by jarring and tamping, followed y welding in hydrogen, and impregnation with active material, as described in my Patent X0. 854,200 granted May 21, 1907.

Improved results will be secure 1 when the pocketsections and grid of each lectrode are plated with cobalt-nickel alloy, instead of with nickel alone, as heretofore, since such a tory granular material capable of being disl l l contact. Such an alloy may be formed of 50 per cent. cobalt and 50 per cent-. nickel, and may be applied by electro-deposition in any suitable way. After this cobalt-nickel plating has been applied, the metal parts are preferably'welded by the application of heat in an inert gas, such as hydrogenyso as to .relieve any condition of tension in thedeposited coating. El

While I prefer to employ scales or flakes of a suitable metal or alloy for forming the sponge-like conducting structure surrounding the active mass, as I thereby obtain the 'greatest porosity with the least" weight of .metal, the same process may be carried out althougha-t a sacrifice of weight, since obviously the relation between the bulk of the metal or alloy and the. cubical contents of the cells or pores, would be much less in the case of the metallic powder than in the case of metallic scales, flakes or foils, so that be commercially inapplicable. Finally, it will be understood that the sponge-like conducting structure may be used for supporting the active material independently of the usualperforated pockets in which case the latter maybe omitted. l consid'er it preferable, however, to use the perforated metallic pockets as they materially strengthen the construction of the electrode, and eii'ectively prevent the active material from scaling off or falling out of the exposed cells or pores at the surface of the spongy mass. Furtheri'more, the perforated pockets protect the l spon y mass effectively against accident, since the mass is somewhat fragile and of butslight tenacity.

with'the metal or alloy in powdered form,

an alloy materially increases the character of the use of metallic powder would probably I I I do not claim?herein specific method v.,descr1b"e'dof foimingr"the.spon y 'or honey 'Qjcomb structure bythe' loose. in reduction of ere, however, "claims in my present applies} 1: mys' aidco-pending case; herein eny 'specrfijo proce 821,626- granted 29;. 1906., referring to [jthegmethod of rnaklngsaidfiakes by elect-r0 granted August 7;. 1906',". refer1 ing to the making of said flakesbzy;precipitation, and in my Patent No; 821,627 "grsnted'May 29,

by sublimation. 1

Ievrngnow by Letters Patent'isas follows:

1'. The process of n-iek'n'g electrodes for storage batteries; which consists in .a.fsso

- cieting a mass 7 of conducting metallic ypert-icles in a cellilleir or honeycon ib firiangiernerlt} 0.

2. The p'rocessf f 9 making electrodes 0r film 'tiil a'jcellular orihoneycomh arrangeinei fi, filld' i f'subjectingthe seine to awelding v h solving; the oxid particles, substantially as teriiperature to secureintegrality'ofthe film o1.scales;. substantiallyas set forth.

.filnis a cellular -or'- honeycomb arrange integralit asse forth-.1

-- 4.. The process of "stentielly asset forth.

" 5.]"The process, of

' storogebitteries, which consists in;coating' refractoryparticles with flake like conductt'ion,- the language .ofwhioh is generic enough to mclude the specific process described in 'Nei h flddl cls i 1906, referring-to' the' in a king of said flakes.

and .in subjecting the-seine to 8, Welding ternf perature' to secure integrality of said" part1;

I; '3. The process. of gmeking, electrodes for? storage -batte'r1'es",wh1ch consists n essoclz t in1ent,"and in subjecting the .s'an1 e to a Weld- 1 1g tem ereture 111' -h -*d rogen "gits to secure y. of the films or ;sca'les; substz'intiallymaking electrodes for storage batteries, which consists, in coating granular materizil with conducting metallic i v filiiis; of scales, in compressing the'ni'ess to se cure- 1col1ere1ice' thereof, and in subj eating the scales orifilms'toawelding te1i1peretu'ije, submaking electrodesffm" storage 'biitteries, which ',eonsists', in coating'l grenuIei -QmeterieI withfconduct'ing ngetallic, fscelesoriihns in c'ompressing the mess to 'se-.

curecoherencejthereof,i and in subjecting the -v scales or films to 211', welding temperature. info;

ing'metzillic scales,- in subjecting the n'iass to pressure, fand'ni then heoting the mass to a, welding te'mpereture'qiiflierebythe 1nctcllic" scales will-be weldedtogether, and in finally r removing theref,rgicto'ly particles-to produce 76 "at sl'aonge-like cellular conducting structure; substantiallj' as set fortln,

. YJI-he jjiioe'essi of making. electrodes for storage ibatteries, .which consists in coating refrectoryparticles with flake-like conductinetcllics'cities, in subjectingthefmess to Y pressure, in'the'n heating the mass to a welding tempereturewhereby the metallic Scales will be welded'together, in removing the refrectory -p-artic les to-produce a sponge-like conductingstructure, and finally in subjecting' the same tojheat in a hydrogen iitinospl 1e'1u'a,"as' and for the pur oses set forth;

-8 "The process of ma ring electrodes for storagebatteries, which consists in applying 5 a. sticky; material to refractory particles,

H mixin therewith flake-like metallic scztles, I 7 described my nvention, what l clann as new there n-end desire to" secure .wherey the particles will be covered by seid scales, in-su'bjectingthe mass to pressure, in their subjecting the mass -to e welding temperature whereby the metallic scales will be welded together, and in finally removingthe refractory particles to. lea' e a}, sponge-like cellular 'stincture', as and for the purposes set forthQ-Qg I 9 ""iheyprocess of making electrodes for storage batteries, which consists in coating. z perticles of msgn'esiu'm oxidwith flake-like Inetzillicysceles; in subjecting the mass to pressure; in then subjecting the compressed mass to;,p.-f lweldin'g temperature to 'weld the metallic; scales together,' and in finellv dis- Qper'eture tofweld the metallic scales together,'

and inv finellyjremoi'ing-the ox'id particles, substantially asset forth-. v v v 111. The process of "filling a; conducting sp ongelike or-c ellular structure with an active I materiel, in'fthe' meke-up of storage battery. electrodes; which consists. in introducing a saturatedsolution of the active material within jt he; cells; and in finally applyingiheat "to. drive'off the solvent and deposit-arm jpre-J cipitate' the ac ive material on the walls of nthe ceflls,substantially as set forth: 7

'I1- 2 Thje'process of'fil-li'ng -a, conducting spdfigQlike or cellular structure with en active mzit'eriel, in the make-up of storage" battery electrodes, which consists in introduc-v a. si tureted'solution ofnickel hydroxid within the cells, and in fin'elly epplyingheat to drive'iofl the 'solvent. and precipit'ate'the forth.

nickel salt on the walls of the cells, substantially as set forth. I

13. Theprocess of filling a conducting spongel like or cellular/structure with an active material, in the make-up of storage battery electrodes, which consists in intro ducin a saturated solution of nickel hy-:

(iron-i within the cells, and in finally applying heat in a rarefied atmosphere to drive oil 1 0 the solvent and preci'itate the nickel salt on the walls of the cc] 5, substantially as set 14.'The process of filling a conducting sponge-like or cellular structure with an active material in the make-u of storage battery electrodes, which consists in introducing therein a saturated ammoniacal solution of nickel hydroxid, finally in applying heat to drive off the ammonia and water to precipitate the nickel salt on the walls of the cells, substantially as set forth,

15. The process of filling a conducting? sponge-like or cellular structure with ani .active material, in the makeup of storage battery electrodes, which consists in introducing therein a saturated ammoniacal solution of nickel h droxid, finally in applying i .heat in a rarefie atmosphere to drive off the ture, in ahy tially as set forth.

drogen atmosphere, subs-tan 1:8. The process of making storage batteryf electrodes, which consists in introducing a sectional'perforated metallic pocketwithin suitable grid and subjecting the same to welding temperature, substantially as set forth.

19. The process of making storage hat tery electrodes which consists in introducing' conducting particles within a pocket, introducing said pocket Within a suitable grid, and in subjecting the same to a welding tempo ature, substantially as set forth.

20. ""he process of making storage batteryelectrodes which consists in associating nickei hydroxid with conducting metallic particles in an inclosing pocket, and securing said pocket within a suitable grid, substantially as set forth.

l 21. The process of making storage battery electrodes, which consists in associating active material with conducting metallic l particles in an inclosing pocket, and securing said pocket Within a suitable grid, substantially as setforth.

22. The process of making storage battery electrodes, which consists in introducing a mass of conducting metallic particles within an inclosing pocket and subjecting the same to a welding temperature, and associating active material therewith, substantially as set forth.

This specification signed and witnessed this 15th day of May, 1907.

THOMAS A. EDISON.

Witnesses l FRANK L. DYER, FRANK D. LEWIS. 

